Method of reenforcing reflectors



Aug.' 5. 1924.

B. BART IBTHOD OF REENFORCING REFLECTORS Filed June 10. 192

Patented Aug. 5, 1924.

UNITED STATES BLASIUS BART; OF NEWARK, NEW JERSEY.

METHOD OF BEENFORCING REFLECTOBS.

Application filed June 10,

To all whom it may concern:

Be it known that I, BLASIUS BART, a citizen of the Republic ofSwitzerland and resident of Newark, in the county of Essex and State ofNew Jersey, have invented certain new and useful Im rovements in -Methods of Reenforcing Re ectors, of which the following is a specification.

The invention relates in general to a method for reenforcingelectrolytically deposited thin sheet metal articles which do notpossess a rigidity sufficient to maintain their configuration under thedistorting effect of their own weight and the invention relatesspecifically to a method of forming a reinforced reflector of a straightor curvilinear form. 4

The invention also relates to an im roved form of reflectors mostconveniently ormed by the method herein featured. Reflectors of the typeunder consideration are usually :formed of a thin film of reflectingmetal, such as silver, with a thin backing sheet of some strengtheningmaterial, such as cop- ,per. Considerations of economy as well as otherfactors require that the combined films be of the least possiblethickness of material. Such reflectors when of relatively smalldiameter, say four or five inches can be made of thickness of materialtdprovide a rigidity in the backing layer suflicient to maintain theconfiguration of the article but when the reflectors are made of largedia meter, say six to ten feet, it is obvious that to produce a backingsufficient to give the rigidity necessary to defeat distortion, would beprohibitive especially in those cases where the backing is made of anexpensive metal such as the electrolytic copper deposit usuallyemployed.

The present disclosure features a means for reenforcing the frail, thindouble sheet reflector so as to withstand any tendency on the part ofthe reflector to sag by its own weight or to become distorted under thevariable temperature conditions incidental to the use of a reflector insearch lights or other situations where intense heat is present.

One of the primary objects of the invention is to attain a simple modeof procedure to provide economically a reinforcement for a device of theclass outlined which will act to maintain the desired configuration tothe object under the variable conditions of use,

1920. serial mi. 887,975.

and at the same time secure the reenforcing stiffening material, such ascopper, on the rear face of the reflecting layer, all as is usual 1n themanufacture of metallic mirrors as at present practiced.

The disclosure features a rigid and preformed reenforcing element ofsuitable form which is placed against the partially formed backing andthe electroplating operation continued until the element is securelyembedded in the backing sheet.

Considering the article'phase of the disclosure the primary object ofthe invention is to provide a well braced reflector in which the use ofmetal has been reduced to a minimum and the necessary strength providedby relatively inexpensive structural parts.

Still another ob ect of the invention is to provide a simple means forarmouring the periphery of the formed reflector so that it may be movedabout onthe armouring means utilized as a rim and so that the armouringmeans may be utilized as a mounting frame for securing the reflector inplace. v Y

Still another object of the invention is to provide a metallic reflectorwhich can be made of unusually large size and which need not have anygreater thickness of metal parts than is necessary for a smallreflector.

Various other objects and advantages of the invention will be in partobvious from an inspection of the accompanying drawings and in part willbe more fully set forth in the following particular description of oneform of mechanism embodying my invention, and the invention alsoconsists in certain new and novel features of construction andcombination of parts hereinafter set forth and claimed.

Referring to the accompanying drawformed reflector assembled with anencircling armouring band for-protecting the edges of the same; and

Fig. 2 is a reduced view in rear elevation of the device shown in Figure1.

In the following description and .in the claims, arts will beidentifiedv by specific names or convenience of expression but they areintended to be as generic in their application to similar parts as theart.. w1l1 permit.

In the accompanying drawings, a reflector has been selectedto'illustrate one form of the resulting product obtained from practicingthe method disclosed. It is to be understood that a very thin film 11.0fSllver has been de osited upon a highly 01'- ished glass mou d as morefully descri ed in my copendin application on apparatus for'spraying soutions, Serial No. 387,974,

filed June 10, 1920. After the silver deposit was set the mould with thesilver film thereon was positioned in an electrolytic vat and a thincopper film deposited on the rear face of the reflecting material as'isusual in such processes." After the film had attainedesome thi'clmess,as indicated at 12, so as to provide a frame spacing layer, thereen'forcing element, such as thefring 13, was' ositione on the copperfilm 12 and the e ectrolytic depositin process continued to form abacking ,s eet14 of the desired thickness. The copper backing embeds thereenforcing ring within its depth so thatthe element is entirelysurrounded with the integral sheet 14 and in this way secured to thereflecting film to form a single united structure.

I In situations such as illustrated wherein there is shown a reflectorof the curvilinear ity to the structure and may be a built-up structurefeaturing the best practices inherent in other internal reinforcementarts. In situations where the element of light weight is a materialfactor, the ring is made of aluminum but in general practice woodenstructures have been found to be preferable for numerous reasons such asresiliencyand cheapness of manufacture.

- Inthose situations where it is desired that the ring form ofreinforcement be used in articles of large diameter it is possible toform the reinforcement in the form of a wheel with internal bracingspokes 15 and this structure is particularly'applicable in the largesized reflectors which are pro- -vided with a central opening 16. Inthis cas'ethe okes are joined to a hub ring 17 which enclrcles theaperture opening 16. In such devices it ispreferable that the hub memberand the part of'the spokes connected thereto be in spaced relation tothe metallic part of the reflector so as to permit the necessary degreeof expansion and contraction usual with the reflectors of high powerlamps.

It is obvious that the securing of the reenforcin element within thebody of the backing ayer eliminates any necessity for providing securingelements which would otherwise have to pass through the metalhe part ofthe reflector to the reflecting surface thus giving rise to anobjectionable ap arance to the front of the device. The re ectordisclosed is firmly braced at its periphery and is finished off .in amanner 'to give a pleasing finish to the-edge and at the same time tominimize the possibility of cracks starting at the edge of therefleeting surface. The back sideof the re- .flector looks as if it isformed entirely of '85 copper. with a thickened edge thus presenting aileasing and complete appearance to the re ector as a whole. Ininstalling the reinforcement in place there is eliminated any necessitof manual labor in fastening the reenforcmg' element to the reflectorfor- ,the' electroplating process acts to secure the frame accurately,positively, and rmanently, and without, in any way, wea ening either thereenforcin frame .or the thin films of metal which go to make up thereflector' proper. v 1 v I Y Refer'ring to a refinement of structuraldetail, it is noted that the outer edge of the -rmg 13 forms a sharpangled projection 13' at its inner side to insure the forming of thecopper into the angle on the outerside of the ring .as it forms'ontheinner side as shown in the thickened rtion.14. The reflector as thu'sdescribe is com late and may be transported and plosition in thereflecting apparatus with w ic'hit is intended to o rate withoutadditional attachments. Tiizse reflectors frequently rolled about fromplace to place in the manner'of rolling a arge wheel and it is deemedadvisable un. der some conditions of use to provide the formed reflectorwith an armouring band 18 resembling the rim of awheel. In theillustrated showing of the invention the perrphery of the reflector hasbeen formed particularly to be received in an annular groove formed inthe inner periphery of the band 18. The. reflector is mounted in theband in a manner similar to the mounting 'of a picture in a frame. Theband illustrated is formed of wood with a metallic coating 18' butthisis of course immaterial and that form of band will be used which s bestsuited to give the strength or pleasin appearance desired. a

e illustrated showing is further coin-v plicated to disclose means forpositively sek curing the band to the reflector. For this purposecountersunk bolts 19' are passed illustrates a collective showing of thesev eral features described and that usually.

there is no need for the armouri rim band nor for the peculiarconfiguration of the periphery of the electrolytically formed parts ofthe reflector.

Having thus described my invention, I claim:

1 In the art of forming a reinforced reflector, the process whichconsists in forming a film of a reflecting substance on a mould,partially forming a layer of strengthenin material as a backing to thereflecting .su stance and to form a frame spacing film of the backingmaterial, positioning a preformed reenforcin element on the film formingsaid partially ormed back ing and'com leting the formation of saidbacking there y to embed the element in the backing material and thussecure the element to the reflector.

2. In the art of reenforcing electrolytically formed reflectors, therocesswhich includes the steps of depositlng electrolytically a layer ofthe substance to be reinforced, positioning a reenforcing element injuxtaposition to the formed layerand continuing the electrolyticaldeposition thereby to form a layer of the substance about parts of. saidelement to secure the same wlthin the integral layer of the substanceformed by the electrolytic deposits. 7

3. In the art of reenforcing electrolytically backed reflectors, therocess which consists in forming a layer 0 the reflecting substance on amould, positioning a reenforcing element in juxtaposition to the exposedface of said formed layer and electrolytically forming a backing to saidformed layer while permitting the backing to extend across thereinforcing element to secure the same in place.

4. In the art of formin metallic reflectors, the process which consistsin depositing a layer of silver on a mould electrolytically depositing alayer of copper on the back of the silver layer, positioning areenforcing element on said copper layer and covering the back of the coper layer and the frame with an additiona backing of copperelectrolytically deposited. I

' 5. A reflector includin a film of reflectin metal on the front sidethereof and provided with a backing of a stiffening material, apreformed rigid reenforcing frame formed ofi a; material difl'erin fromthe stiffening material and embed ed in said stiffening material.

6. A metallic reflector including a thin sheet of metal, constitutingthe reflecting surface, said sheet being of insuflicient mass tomaintain its configuration, a reenforcing frame secured to the thinsheet of metal 'to maintain the reflector in its prescribed shape. v

' 7 A curvilinear reflector including a thin film of reflecting metal,free of securing apertures, a backing of stiffening material formed onthe back of the reflecting metal film and a reenforcing frame formaintaining the reflector in position, said frame being secured to thereflecting sheet by the stifl'ening material and secured coeval withtheformation of the backing.

8. A curvilinear reflector including a thin film of reflecting metal, abacking of stlfi'ening material formed on the back of the reflectingmetal film, and a self-sustaining reenforcing frame. for maintaining thereflector in. position, said frame being secured to the reflecting sheetby the stiffening material and embedded .in the stiffening material andconcealed thereby.

9. A reflector comprising three elements forming a unitary structure andincluding solely a film of reflecting metal, a sheet of metal forming abacking for the reflecting metallic film and an element for reenforcingthe sheet and film, said element being intimately associated with thebacking and free of fastenin means.-

10. A re ector having a thin layer of reflecting material defining thefront side, a layer of strengthening metal defining the back side and aself-sustaining reenforcing frame secured to the reflecting layer andconcealed b the back'strengthening layer.

11. A re ector, including a thin layer of reflecting metal defining itsvfront face, a frame atthe rear side of the reflecting surface andoutlining the periphery of the reflector and an electrolytlcallydeposited layer of metal securing the frame to the reflecting layer.

12. A curvilinear reflector, including a I thin layer of reflectingmetal defining its front face, a circular frame at the rear sidesustaining reenforcing frametherefor, having parts thereof outlining thereflector, embedded in and surrounded by the outer portion of thebacking la er.

14. A reflector inclu' ing a thin front layer of a reflecting materialand a thin backing layer in. engagement therewith,

said layers being of insuflicient rigidity to maintain the configurationof thereflector, a reenforcing frame therefor havin parts thereofoutlining the reflector and em (led in the outer portion of the backinglayer and said frame includin other partsfree of the backing layer tereby permittingrelative movement between the backing layer and saidfree arts.

15. In a device 0 the class described, the combination with a reflectorhaving a copper coated periphery formed electrolytically, of anarmouring band similarly, coated and encircling said periphery to form arim for the reflector. and-with the :contacting surfaces-between tliereflector-and rim of the same metal.

- 16. In a device of the class described, the

combination with a reflecto'r'having a thin ing the periphery of thereflector and said,

"and including solely a film 0 central portion and a periphery formedelectrolytic-ally and having a greater thickness than the centralportion of the reflec-' tor, ofan armouring band encircling saidperiphery to form a rim for the reflector, said band provided with arecess for receivpenphery and band coacting to maintain theconfiguration of the reflector.

17. 'In a device of the class described, the combination with areflector having a periphery formed electrolytically, of an armouringband encircling said periphery to form. a rim for thereflector and meansfor securing the band tothe reflector said means being in spacedrelation to its reflecting surface.

18. A reflector having a thin layer of reflecting material defining thefront side, a layer of strengthenin material defining the back side,means for maintaining the shape of the reflectorsecured to thereflecting layer by the-back strengtheninglayer and positionedrearwardly of the reflecting material and a reenforcing band encirclingsaid means as well as the reflecting material. A

19. A curvilinear reflector comprising three elements forming a unitarstructure reflecting metal, a sheet of metal forming a backing for thereflecting metallic film. an elementfor reenforcing the sheet and film,said element being intimately associated with the backing and freeof,fastening means, said backing extending homogeneously about theelement and a band encircling the periphery of said reflector.

20. A curvilinear reflector comprisingthree elements forming a umtarystructure and including solely a film of reflecting metal, 'a sheet ofmetal forming a backing forthe reflecting metallic film, anelement forreinforcing the sheet and film, said element [being intimatelyfassociatedwith the backing and free of fastening means, a

means band encircling the periphery of said reflector and bolts assmgthroughthe band and reinforcing e ement.

21. A metallic mirror composed of an opaque film of chemically depositedsilver,

the same having a reflecting surface which I is the counterpart of anoptically ound and polished mold a baekin for sai silver film andastiifening ringorming part of said backing. 1 22. A mirror, having anexposed reflecting surface of deposited silver reinforcedby anelectrolytic backing of copper superimposed upon the, silver andastiffening ring electrically soldered to thecopper' at the edge of thereflecting. surface; P

23. A mirror, having an exposed'reflect-i ing surface of chemicallydeposited silver reinforced by an electrolytic backing of copper, astiffening ring electrolytically so dered to the silver and copper atthe edge of the reflecting surface and a backing of copper anchored tothe edge ring. 24. mirror, having an exposed reflect ing surface. ofchemically deposited silverv reinforced by an electrolytic backing ':ofco per, a stiffening ring electrolytically so dered to the silver andcopper at the edge of the reflecting surface and azbacking of copperanchored to the electrolytic deposit ofcopper and to the edge ring. 25.A-mirror, having an exposed reflect. in surface of chemically depositedsilver reinforced by an electrolytic backing of copper superimposed uponthe silver, 9.-

stiifening ring electrolytically soldered to .the silver and copper atthe edge of the reflecting surface, said ring havin a rabbeted outer ede, and a backing 0 copper interlocked wit said rabbeted edge.

ing surface of chemically deposited silver reinforced by an electrolyticbacking of ice 26. A mirror, having an exposed refleetcoppersuperimposed .upon, the silver, a v I copper superimposed upon thesilver, stifiening the silver deposits by applying a backing material tothe copper, and removing the mirror from the form.

28. The process of making a mirror of the desired shape, which consistsin chemical] depositing silver on a formof highly p3 yv eished lass,reenforcing the chemical posite silver by an electrolytic'deposit-of'cop r superimposing 'upon the copper an additidnal electrolytic depositof copper and j by the latter soldering a stiffening edge ring ing thecopper deposit by a backing rein-t forced by a shell, and removing themirror from the form.

30. The process of producing a mirror of the desired shape whichconsists in chemically depositing silver on a form of highly polishedglass, reenforcing the chemically deposited silver by an electrolyticbacking of copper superimposed upon the silver, stiffemng the copperbacked silver layer so formed by a backing and removing the mirror fromthe form.

31. A mirror, having an exposed reflecting surface of chemicallydeposited silver reinforced by an electrolytic backing of coppersuperimposed vupon the silver, a stifltening ring electrolyticallysoldered to the copper at the edge of the reflecting surface, a centralopening in the reflecting surface and a stiffening central ring aroundthe central opening and secured to the silver and copper.

- 32. A mirror, having an exposed reflecting surface of chemicallydeposited silver reinforced by an electrolytic backing of coppersuperimposed upon the silver, a stiffening ring electrolyticallysoldered to the copper at the edge of the reflecting surface, a centralopening in the reflecting surface, a stiffening central, ring around thecentral opening to the silver and copper, and a backing over the copperanchored to the edge ring.

33. A mirror, having an exposed reflecting surface of chemicallydeposited silver reinforced by an electrolytic backing of coppersuperimposed upon the silver, a stiffening ring electrolyticallysoldered to the copper at the edge of the reflecting surface, a backingof copper anchored to the edge ring, and a metal shell reinforcementsecured to the ring.

34. A mirror, having an exposed reflecting surface of chemicalldeposited silver reinforced by an electro ytic backing of coppersuperimposed upon the silver, a stiffening ring electrolyticallysoldered to the copper at the edge of the reflecting surface, and a-metal shell formed with perforations and fastening means insaidperforations for securing the shell to the stiffening ring.

Signed at New York city, in the county of New York and State of NewYork, this 17th day of May, A. D. 1920.

BLASIUS .BART.

